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Article
Publication date: 15 November 2018

Leander Schmidt, Klaus Schricker, Jean Pierre Bergmann, Felix Hussenöder and Mathias Eiber

This study aims to characterize the suitability of a direct extrusion process in the fused layer manufacturing (FLM)-method under processing of granulated plastics.

Abstract

Purpose

This study aims to characterize the suitability of a direct extrusion process in the fused layer manufacturing (FLM)-method under processing of granulated plastics.

Design/methodology/approach

In this paper, a granulate-based direct extrusion system in the FLM method is presented. This system is characterized with respect to the strand deposition mechanism and resulting component properties (geometrically and mechanically).

Findings

The extruder output could be identified as a linear relation between the applied extruder speed and the resulting mass flow. A developed model for the material and temperature-dependent strand deposition process was validated under experimental investigations. Further, it was possible to define process windows to realize desired strand widths and strand heights. In addition, analyses were conducted to determine the tensile strength transversely to the orientation of the layer plane.

Research limitations/implications

The extrusion system was characterized under the processing of materials ABS Magnum 8434 and PLA Ingeo 4043D. Due to the restricted choice of materials, further investigations are planned under an extension of the test materials. Furthermore, the degree of the geometric complexity of the test components should be increased to finally characterize the process.

Originality/value

By means of the characterization of the direct extrusion system, it is possible for users to classify the process and to use the process in specific application areas. In comparison to filament-based extrusion systems, significant advantages can be achieved by means of direct extrusion. These include, for example, the use of less expensive work materials (by factor >10), the use of existing test certificates and the advantage of higher mechanical properties. This makes it possible to meet modern product requirements and to produce competitive components.

Details

Rapid Prototyping Journal, vol. 25 no. 1
Type: Research Article
ISSN: 1355-2546

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